Flame retardant properties of plasma pre-treated/diamond-like carbon (DLC) coated cotton fabrics

Textiles with superior anti-flammability properties combined with minimal environmental impact are extremely necessary to reduce fire-related issues. In this regard, diamond-like carbon (DLC) coatings on cotton fabrics may represent promising candidates as potential flame-retardant (FR) materials. Herein, superhydrophobic and fire-resistant cotton fabrics were fabricated through a two-step plasma strategy by alternately exposing substrates to H₂ and O₂ plasma pre-treatments and subsequent DLC deposition. Fourier transform-infrared spectroscopy analysis has revealed that different plasma pre-treatments can impose surface modifications on the chemical structure of cotton, especially in carboxylic and hydroxyl groups, leading to a radical alteration of surface roughness and of the crystalline cellulosic external structure. These changes deeply influenced the growth of DLC thin films and the surface properties of cotton fabric because of the combination of a hierarchical structure and surface chemistry as verified using field emission gun-scanning electron microscopy and water contact angle measurements. The effects of both specific gases used in the pre-treatment step and duration of pre-treatment were analysed and compared using thermogravimetric analyses. The H₂-pre-treated DLC cottons exhibited good potential as an FR material, showing improved thermal stability in respect to untreated cotton, as evidenced by increased ignition times. Moreover, vertical burning tests have demonstrated that DLC-cotton systems exhibit enhanced flammability resistance.